lunar excavation systems at the colorado … · lunar excavation systems at the colorado school of...
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LUNAR EXCAVATION
SYSTEMS AT THE
COLORADO SCHOOL OF
MINES
Christopher Dreyer
Paul van Susante
Tue. 10/5/2010
Workshop for the Lunar Applications of Mining and Mineral
Beneficiation
October 5-7, 2010
Montana Tech/University of Montana , Butte, MT
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Value of Student projects to the ISRU community
• The ISRU community is composed of scientists and engineers in government, academia and industry.
• Varied institutional structures, contracting requirements, practices, skills, knowledge, etc…
• Each member of the community brings strengths and weaknesses to the problems.
• Undergraduate student teams can introduce new ideas at low cost to the community.
• Increasing the volume of projects will enable the contribution from this group to grow.
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Overall CSM Integrated Picture
0 0.05 0.1 0.15 0.2 0.25 0.30
5
10
15
20
25
30
35
40
45
50GRC1 - Horizontal Force
Cutting Depth (m)
Forc
e (
kN
)
Osman
Gill & vdBerg / Blouin
Swick & Per
Mckyes
Luth & Wismer
Balovnev
Zeng
Qinsen
5000 lbf line
FEA data
Chariot data
Analysis, theory
FE / analytical work
Lab - testing Field testing
Prototypes
Science & System Engineering Inclusion
Bucketwheel
Bucket Ladder: III, IV,
V
Backhoe
Bucketladder I
Trommel Sorter
Force Measurements
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Bucketwheel
To function at 50 kg/hr → auger → directly into processing unit → discard proceeds
Problems with the auger, excavation and transport are separate systems
Tim Muff, CSM MS Engineering
Lead to the Lockheed Bucket Drum
Another CSM Senior Design Project: a system to move
Lockheed Bucket Drum off a lander
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Bucketladder I, II
500 kg/hr, transport, dump into collection bin
Combines excavation and transport into the same system
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Bucketladder IIIa, b
• Bucketladder on a rover, 1500 kg/hr, transport, dump
into collection bin, dump in processing unit using ramp
• Competed in the Centennial Challenge in ‘08 & ‘09
• Autonomy system in 2008 got it stuck in a corner
• In 2009 it got stuck on rocks and had inadequate sensing
and imaging for the controllers to know how to get
unstuck
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Bucketladder IV, V• Lunabotics Competition
Integrated with rover, 1500 kg/hr, transport, dump into collection bin, dump in
processing unit by lifting collection bin
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Before After
Excavation at SRR demo Dumping
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Excavation Power Use
Centennial Challenge Bucketladder I Bucketwheel
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Backhoe Prototype
Integrated with rover true ‘quick connect’, 100 kg/hr, 1m depth, 30 in3 of material
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Force Measurements
Testbed to measure x, and y forces
Tim Muff, Lee Johnson, Andrew Brewer, Faculty Advisor Bob King
’09-’10 Senior Design: Modified testbed to fly on 1/6th gravity campaign
’10-’11 Senior Design: working on improvements to testbed and hope to
participate in NASA Microgravity University, client: KSC Surface Systems Group
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Regolith Goes In
Fine Regolith Out
Fragments Out
• ISRU: Oxygen production – Separate large fragments from
fines. Civil Engineering – Sort fines, coarse, etc…
use for road bed, landing pad, high traffic areas, etc…
• Science: Apollo Rake samples were excellent source of
variety: pristine crustal rocks, impact melt rocks, and
basalts.1
1: G. Lofgren, “Experience from Apollo and Challenges to Geology”, presentation, OSEWG, Workshop on Robots Supporting Human Science and
Exploration, Houston TX, August 2009.
Objective to separate >2mm fragments from fines intended
for 600 kg/hr rate of input regolith
Plan to mount sifter on excavator to sort simultaneous with
excavation. Only the desired size fraction goes to the hopper.
Wire Mesh
Diameter = 25cm; Length = 50cm
Beneficiation: Regolith Sifter Trommel
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
• Trommel Equation:
where:
M=mass feedrate
g = Gravitational acceleration
b = thickness of material within trommel
ρ = density of material
β = Angle of Inclination
R = Trommel Radius
α = riding angle
ω = angular frequency
δ = angle of impingement
t = flight time
2/32/1RbgM ρβψ=
)cossincos(sin δααωαψ ++= t
Trommel Theory (Alter et al.):
( )αω
sin2
=g
R
H. Alter, J. Gavis, M. L. Renard, “Design Models of Trommel for Resource Recovery Processing”, Resources and Conservation, Volume 6, Issues 3-4,
November 1981, Pages 223-240.
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Students:• David Hall, BS Physics 2010
Physics Senior Design Fall ’09, Spr ’10• Stephanie Quintana, BS Evn Eng 2011
CSM Space Internship Summer 2010 Colorado Space Grant
25cm diameter; 50cm lengthSteel woven wire clothSquare mesh 1.85 mm open widthInclination angle: 3°to 9.3°
Assuming several values in the trommelequation to size for 600kg/hr in lunar gravity
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Simulants used• Need a simulant with large particle size – made two:
1. Granite based by David Hall, Physics Senior Design
From a local landscape supply yard, geological source unknown.
2. Vesicular Basalt based by Stephanie Quintana, CSM Space Internship Colorado Space Grant
Grinding provided by Zybek Advanced Products
• Objectives: Excavation requires large quantities
– Reasonable for excavation and mechanical testing
– low cost commerical source material
– Characterize the simulant
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
• Vesicular Basalt (CSM-CL)
Colorado Lava, Inc; T.O. Mine
in Colfax County, New
Mexico, SE of Raton
+36°49' 22.72", -104°9' 17.47" elevation 7264 ft
Geological map location classified
as “Basalt or basaltic andesite”
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
• Crushing Process, Fines– Zybek Advanced Products (ZAP) donated use
of the Aerodynamic Impact Reactor (AIR)
scale represents 50 microns
CL-S CL-F
Large fragments
• CSM Mining Department, Jaw and Roll crusher
• Ro-tap sifter for size fractions
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
x-ray fluorescence measurements
Normative analysis:
“extremely alkaline basalt”
Thanks to D. Stoeser and D. Rickman
Sample SCM-CL-S
SiO2 47.9
Al2O3 17.2
TiO2 1.58
Fe2O3 11.7
MgO 6.44
MnO 0.24
CaO 8.93
Na2O 3.95
K2O 2.42
P2O5 0.98
Total 101.34
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Trommel Conclusions:
1) Fines fall through the mesh readily. Will this be true in lunar gravity?
2) Sorting rate is below the anticipated rate (600kg/hr in lunar gravity):
~30kg/hr at best using CSM-CL-2 (2-4mm basalt-based simulant)
The >2mm fraction is <10% of lunar regolith, with the <2mm fraction added in the rate is ~300-600kg/hr. (assumes fines fall through readily)
Equivalent to 50-100kg/hr in lunar gravity
Tests used the large size fraction only DG >2mm, CL 2-4mm split. Fines readily fell through the mesh.
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Thanks to STUDENTS (Free (cheap) Labor)
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
The faculty:
• Mike Duke – Bucketwheel, early bucketladder, former CSR Director
• Bob King – excavation force measurements
• Masami Nakagawa – Faculty Advisor for the First Centennial Excavation Rover
• Paul van Susante – Bucketladder, excavation force measurement modeling, Faculty Advisor to Senior Design Groups (via Adjunct teaching), NASA 2010 ESMD Summer Faculty Fellow at KSC Surface Systems Group
• Chris Dreyer – Faculty advisor to 2nd Centennial Excavation Rover, Senior Design Client to Lunabotics Competition Teams (2010 and 2011)
• Angel Abbud-Madrid – Funding from CSR, occasionally a Senior Design Client
• Bob Knecht – EPICS projects, Colorado Space Grant, CSM Summer Space Internship
• Joel Duncan – EPICS projects
• Jeff Andrews-Hanna – Geophysics, CSM Summer Space Internship
The Funding
• Colorado Space Grant
• Center for Space Resources (CSR)
• Industrial Sponsors
• NASA Grants
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Measuring Success Rate
of student lead projects in terms of…
1. Education – all have been successful
a) Students learn lessons with hands on engineering projects
that are often new to them.
b) Train future engineers/scientists in ISRU technology
2. Engineering R&D – varied results
a) Few produce a result similar to professional projects.
b) Expect 1 in 3 to fail completely, 1 in 3 to be great and the
rest to be somewhere in between.
c) Don’t expect a stellar performance every time from any
particular team.
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Conclusions• Undergraduate student project teams have value to
the ISRU community; unique capabilities & limitations.
• The value is improved with quantity.
→ Competitions are a great way to do it: dozens of
groups and universities work on the same problem.
• Focused projects with well defined objectives are
necessary for good R&D value.
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Workshop for the Lunar Applications of Mining
and Mineral Beneficiation, October 5-7, 2010
Questions?